Heterocyclic nitrogen containing polymers coated analyte monitoring device and methods of use

ABSTRACT

The present invention is directed to membranes composed of heterocyclic nitrogen groups, such as vinylpyridine and to electrochemical sensors equipped with such membranes. The membranes are useful in limiting the diffusion of an analyte to a working electrode in an electrochemical sensor so that the sensor does not saturate and/or remains linearly responsive over a large range of analyte concentrations. Electrochemical sensors equipped with membranes described herein demonstrate considerable sensitivity and stability, and a large signal-to-noise ratio, in a variety of conditions.

BACKGROUND OF THE INVENTION

Enzyme-based biosensors are devices in which ananalyte-concentration-dependent biochemical reaction signal is convertedinto a measurable physical signal, such as an optical or electricalsignal. Such biosensors are widely used in the detection of analytes inclinical, environmental, agricultural and biotechnological applications.Analytes that can be measured in clinical assays of fluids of the humanbody include, for example, glucose, lactate, cholesterol, bilirubin andamino acids. The detection of analytes in biological fluids, such asblood, is important in the diagnosis and the monitoring of manydiseases.

Biosensors that detect analytes via electrical signals, such as current(amperometric biosensors) or charge (coulometric biosensors), are ofspecial interest because electron transfer is involved in thebiochemical reactions of many important bioanalytes. For example, thereaction of glucose with glucose oxidase involves electron transfer fromglucose to the enzyme to produce gluconolactone and reduced enzyme. Inan example of an amperometric glucose biosensor, glucose is oxidized byoxygen in the body fluid via a glucose oxidase-catalyzed reaction thatgenerates gluconolactone and hydrogen peroxide, then the hydrogenperoxide is electrooxidized and correlated to the concentration ofglucose in the body fluid.

Some biosensors are designed for implantation in a living animal body,such as a mammalian or a human body, merely by way of example. In animplantable amperometric biosensor, the working electrode is typicallyconstructed of a sensing layer, which is in direct contact with theconductive material of the electrode, and a diffusion-limiting membranelayer on top of the sensing layer. The sensing layer typically consistsof an enzyme, an optional enzyme stabilizer such as bovine serum albumin(BSA), and a crosslinker that crosslinks the sensing layer components.Alternatively, the sensing layer consists of an enzyme, a polymericredox mediator, and a crosslinker that crosslinks the sensing layercomponents, as is the case in—“wired-enzyme” biosensors.

In an implantable amperometric glucose sensor, the membrane is oftenbeneficial or necessary for regulating or limiting the flux of glucoseto the sensing layer. By way of explanation, in a glucose sensor withouta membrane, the flux of glucose to the sensing layer increases linearlywith the concentration of glucose. When all of the glucose arriving atthe sensing layer is consumed, the measured output signal is linearlyproportional to the flux of glucose and thus to the concentration ofglucose. However, when the glucose consumption is limited by the rate ofone or more of the chemical or electrochemical reactions in the sensinglayer, the measured output signal is no longer controlled by the flux ofglucose and is no longer linearly proportional to the flux orconcentration of glucose. In this case, only a fraction of the glucosearriving at the sensing layer is contributing to the current. Thecurrent no longer increases linearly with the glucose concentration butbecomes saturated, meaning that it increases less and less for a givenincrement of glucose concentration, and eventually stops increasing withthe concentration of glucose. In a glucose sensor equipped with adiffusion-limiting membrane, on the other hand, the membrane reduces theflux of glucose to the sensing layer such that the sensor does notbecome saturated, or becomes saturated only at much higher glucoseconcentrations and can therefore operate effectively resolve an increasein the concentration of glucose when the glucose concentration is high.

There have been various attempts to develop glucose-diffusion-limitingmembranes. The membranes were, however, usually made of polymers, andeither their average thickness and/or the microscopic uniformity oftheir thickness was difficult to control and/or reproduce. As a result,the glucose fluxes through the membranes, which determined thesensitivities of the glucose sensors employing such membranes werewidely scattered, indicative of lack of adequate control in themembrane-making process. Thus, there is a need for aglucose-diffusion-limiting membrane that provides adequate regulation ofthe flux of glucose to the sensing layer and that is mechanicallystrong, biocompatible, and easily and reproducibly manufactured.

In an implantable amperometric glucose or other analyte sensor, themembrane can be also beneficial or necessary for regulating or limitingthe flux of an interferant to the sensing layer, the interferantaffecting the signal, for example the current produced by the analyte.By affecting the signal, the interferant adds to the measurement'serror. The preferred membranes reduce the flux of the interferant morethan they reduce the flux of the analyte, for example of glucose.

SUMMARY OF THE INVENTION

The present application is directed to membranes composed ofheterocyclic nitrogen groups, such as vinylpyridine and toelectrochemical sensors equipped with such membranes. The membranes areuseful in limiting the diffusion of an analyte to a working electrode inan electrochemical sensor so that the sensor does not saturate and/orremains linearly responsive over a large range of analyteconcentrations. Electrochemical sensors equipped with membranesdescribed herein demonstrate considerable sensitivity and stability, anda large signal-to-noise ratio, in a variety of conditions.

Described herein is an electrochemical sensor, including a workingelectrode having a sensing layer in contact with a conductive materialof the electrode; a membrane disposed over the sensing layer, whereinthe membrane comprises a crosslinker and a polymer having the formula:

wherein the solid horizontal line represents a polymer backbone and n isa positive integer; and a counter electrode in electrochemicalcommunication with the working electrode.

In some embodiments, the sensing layer of the working electrode includesa glucose-responsive enzyme. In some embodiments, the sensing layer ofthe working electrode comprises a redox mediator. In certainembodiments, the redox mediator includes a complex selected from thegroup consisting of a ruthenium-containing complex and anosmium-containing complex. In certain embodiments, the redox mediator isnon-leachable with respect to the working electrode. In certainembodiments, the redox mediator is immobilized on the working electrode.

In some embodiments, the polymer comprises the formula:

wherein n is a positive integer. In some embodiments, the crosslinkercomprises a poly(ethylene glycol). In certain embodiments, thepoly(ethylene glycol) is a poly(ethylene glycol) diglycidyl ether. Insome embodiments, the membrane limits flux of glucose or lactatethereacross. In some embodiments, the membrane limits flux of glucose orlactose thereacross in vivo.

Also described herein is an electrode for use in a biosensor, includinga sensing layer in contact with a conductive material of the electrode,and a membrane disposed over the sensing layer, wherein the membranecomprises a crosslinker and a polymer having the formula:

wherein the solid horizontal line represents a polymer backbone and n isa positive integer.

In some embodiments, the sensing layer of the working electrode includesa glucose-responsive enzyme. In some embodiments, the sensing layer ofthe working electrode comprises a redox mediator. In certainembodiments, the redox mediator includes a complex selected from thegroup consisting of a ruthenium-containing complex and anosmium-containing complex. In certain embodiments, the redox mediator isnon-leachable with respect to the working electrode. In certainembodiments, the redox mediator is immobilized on the working electrode.In some embodiments, the polymer comprises the formula:

wherein n is a positive integer. In some embodiments, the crosslinkercomprises a poly(ethylene glycol). In certain embodiments, thepoly(ethylene glycol) is a poly(ethylene glycol) diglycidyl ether. Insome embodiments, the membrane limits flux of glucose or lactatethereacross. In some embodiments, the membrane limits flux of glucose orlactose thereacross in vivo.

Also described herein is an analyte sensor assembly, including anelectrochemical sensor having a flexible substrate comprising (i) atleast one working electrode comprising a sensing layer and a membranedisposed over the sensing layer, wherein the membrane comprises acrosslinker and a polymer having the formula:

wherein the solid horizontal line represents a polymer backbone and n isa positive integer, (ii) at least one counter electrode, and (iii) atleast one contact pad coupled to each of the working and counterelectrodes, wherein the electrochemical sensor is adapted forimplantation of a portion of the electrochemical sensor comprising theworking and counter electrodes through skin; and an electrochemicalsensor control unit comprising (i) a housing adapted for placement onskin; (ii) a plurality of conductive contacts disposed on the housingand configured for coupling to the contact pads of the electrochemicalsensor; and (iii) an rf transmitter disposed in the housing and coupledto the plurality of conductive contacts for transmitting data obtainedusing the electrochemical sensor.

In some embodiments, the sensing layer of the working electrode includesa glucose-responsive enzyme. In some embodiments, the sensing layer ofthe working electrode comprises a redox mediator. In certainembodiments, the redox mediator includes a complex selected from thegroup consisting of a ruthenium-containing complex and anosmium-containing complex. In certain embodiments, the redox mediator isnon-leachable with respect to the working electrode. In certainembodiments, the redox mediator is immobilized on the working electrode.In some embodiments, the polymer comprises the formula:

wherein n is a positive integer. In some embodiments, the crosslinkercomprises a poly(ethylene glycol). In certain embodiments, thepoly(ethylene glycol) is a poly(ethylene glycol) diglycidyl ether. Insome embodiments, the membrane limits flux of glucose or lactatethereacross. In some embodiments, the membrane limits flux of glucose orlactose thereacross in vivo.

Also described herein is a method for monitoring a level of an analyteusing the analyte monitoring system including, inserting theelectrochemical sensor into skin of a patient; attaching theelectrochemical sensor control unit to the skin of the patient; couplinga plurality of conductive contacts disposed in the sensor control unitto a plurality of contact pads disposed on the sensor; collecting data,using the sensor control unit, regarding a level of an analyte fromsignals generated by the sensor; transmitting the collected data to thedisplay unit using the rf transmitter of the sensor control unit; anddisplaying an indication of the level of the analyte on the display ofthe display unit.

In some embodiments, the analyte is glucose. In some embodiments, thepolymer comprises the formula:

wherein n is a positive integer. In some embodiments, the crosslinkercomprises a poly(ethylene glycol). In certain embodiments, thepoly(ethylene glycol) is a poly(ethylene glycol) diglycidyl ether. Insome embodiments, the collecting data includes generating signals fromthe sensor and processing the signals into data. In some embodiments,the data includes the signals from the sensor. In certain embodiments,the method further includes activating an alarm if the data indicates analarm condition. In certain embodiments, the method further includesadministering a drug, such as insulin, in response to the data. In someembodiments, the method further includes obtaining a calibration valuefrom a calibration device to calibrate the data. In some embodiments,the calibration device is coupled to the display unit. In someembodiments, the method further includes transmitting the calibrationvalue from a transmitter in the display unit to a receiver in the sensorcontrol unit.

These and other objects, advantages, and features of the invention willbecome apparent to those persons skilled in the art upon reading thedetails of the invention as more fully described below.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is best understood from the following detailed descriptionwhen read in conjunction with the accompanying drawings. It isemphasized that, according to common practice, the various features ofthe drawings are not to-scale. On the contrary, the dimensions of thevarious features are arbitrarily expanded or reduced for clarity.Included in the drawings are the following figures:

FIG. 1 is a calibration curve for two sensors (PVP1 and PVP2) havingdiffusion-limiting membranes described herein were testedsimultaneously, both at 37° C. The sensors were placed in a PBS-bufferedsolution (pH 7) and the output current of each of the sensors wasmeasured over time.

FIG. 2 is a calibration curve for two sensors (PVP1 and PVP2) havingdiffusion-limiting membranes described herein were testedsimultaneously, both at 37° C. The sensors were placed in a PBS-bufferedsolution (pH 7) and the output current of each of the sensors wasmeasured over various concentrations of glucose (mM).

FIG. 3 is a stability curve for two sensors having diffusion-limitingmembranes described herein were tested simultaneously. Each of thesensors was placed in a PBS-buffered solution (pH 7) at variousconcentrations of glucose, and the output current of each of the sensorswas measured at either room temperature (RT) or used after storage for 1week at 56° C. (56 C/1 wk). The measured output currents (nA) wereplotted against concentrations of glucose (mM).

FIG. 4A is a is a schematic, side-view illustration of a portion of atwo-electrode glucose sensor having a working electrode, a combinedcounter/reference electrode, and a dip-coated membrane that encapsulatesboth electrodes, according to the present invention.

FIG. 4B is a schematic top-view illustration of the exemplary sensor ofFIG. 4A.

FIG. 4C is a schematic bottom-view illustration of the exemplary sensorof FIG. 4A.

FIG. 5 is a schematic perspective view of a transcutaneouselectrochemical sensor as it would be seen partially implanted into theskin

Before the present invention is described, it is to be understood thatthis invention is not limited to particular embodiments described, assuch may, of course, vary. It is also to be understood that theterminology used herein is for the purpose of describing particularembodiments only, and is not intended to be limiting, since the scope ofthe present invention will be limited only by the appended claims.

Where a range of values is provided, it is understood that eachintervening value, to the tenth of the unit of the lower limit unlessthe context clearly dictates otherwise, between the upper and lowerlimits of that range is also specifically disclosed. Each smaller rangebetween any stated value or intervening value in a stated range and anyother stated or intervening value in that stated range is encompassedwithin the invention. The upper and lower limits of these smaller rangesmay independently be included or excluded in the range, and each rangewhere either, neither or both limits are included in the smaller rangesis also encompassed within the invention, subject to any specificallyexcluded limit in the stated range. Where the stated range includes oneor both of the limits, ranges excluding either or both of those includedlimits are also included in the invention.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. Although any methods andmaterials similar or equivalent to those described herein can be used inthe practice or testing of the present invention, some potential andpreferred methods and materials are now described. All publicationsmentioned herein are incorporated herein by reference to disclose anddescribe the methods and/or materials in connection with which thepublications are cited. It is understood that the present disclosuresupercedes any disclosure of an incorporated publication to the extentthere is a contradiction.

It must be noted that as used herein and in the appended claims, thesingular forms “a”, “an”, and “the” include plural referents unless thecontext clearly dictates otherwise. Thus, for example, reference to “acell” includes a plurality of such cells and reference to “the compound”includes reference to one or more compounds and equivalents thereofknown to those skilled in the art, and so forth.

The publications discussed herein are provided solely for theirdisclosure prior to the filing date of the present application. Nothingherein is to be construed as an admission that the present invention isnot entitled to antedate such publication by virtue of prior invention.Further, the dates of publication provided may be different from theactual publication dates which may need to be independently confirmed.

DETAILED DESCRIPTION OF THE INVENTION

The present application is directed to membranes composed ofvinylpyridine groups and to electrochemical sensors equipped with suchmembranes. The membranes are useful in limiting the diffusion of ananalyte to a working electrode in an electrochemical sensor so that thesensor does not saturate and/or remains linearly responsive over a largerange of analyte concentrations. Electrochemical sensors equipped withmembranes described herein demonstrate considerable sensitivity andstability, and a large signal-to-noise ratio, in a variety ofconditions.

In general, a membrane described herein is formed by crosslinking amodified polymer containing heterocyclic nitrogen groups in analcohol-buffer mixed solvent and allowing the membrane solution to cureover time. The resulting membrane is capable of limiting the flux of ananalyte from one space, such as a space associated with a biofluid, toanother space, such as space associated with an enzyme-containingsensing layer. A “biological fluid” or “biofluid” is any body fluid orbody fluid derivative in which the analyte can be measured, for example,blood, interstitial fluid, plasma, dermal fluid, sweat, and tears. Anamperometric glucose sensor constructed of a wired-enzyme sensing layerand a glucose-diffusion-limiting layer described herein is very stableand has a large linear detection range.

Diffusion Limiting Membranes

The diffusion limiting membranes include polymers having heterocyclicnitrogen groups and have the following general formula I:

wherein the horizontal line represents a polymer backbone and n is apositive integer from about 150 to about 15,000, including about 500 toabout 12,000, about 750 to about 10,000, about 1,000 to about 9,000,such as about 1,500, 2,000, 2,500, 5,000, 7,000, etc. The term“heterocyclic nitrogen group” refers to a cyclic structure containing anitrogen in a ring of the structure.

In certain embodiments, the polymer backbone further includes acopolymer component, referred to herein as “D”. Examples of copolymercomponents include, but are not limited to, phenylalkyl, alkoxystyrene,hydroxyalkyl, alkoxyalkyl, alkoxycarbonylalkyl, and a moleculecontaining a poly(ethylene glycol) or polyhydroxyl group. Somepoly(heterocyclic nitrogen-co-D) polymers suitable as starting materialsare commercially available. For example,poly(2-vinylpyridine-co-styrene), poly(4-vinylpyridine-co-styrene) andpoly(4-vinylpyridine-co-butyl methacrylate) are available from AldrichChemical Company, Inc. Other poly(heterocyclic nitrogen-co-D) polymerscan be readily synthesized by anyone skilled in the art of polymerchemistry using well-known methods. For example, D is a styrene or aC1-C18 alkyl methacrylate component of a polyvinylpyridine-poly-D, suchas (4-vinylpyrine-co-styrene) or poly(4-vinylpyridine-co-butylmethacrylate). D may contribute to various desirable properties of themembrane including, but not limited to, hydrophobicity, hydrophilicity,solubility, biocompatibility, elasticity and strength. D may be selectedto optimize or “fine-tune” a membrane made from the polymer in terms ofits permeability to an analyte and its non-permeability to anundesirable, interfering component, for example.

The heterocyclic nitrogen groups of Formula I include, but are notlimited to, pyridine, imidazole, oxazole, thiazole, pyrazole, or anyderivative thereof. In some embodiments, the heterocyclic nitrogengroups are vinylpyridine, such as 2-, 3-, or 4-vinylpyridine, orvinylimidazole, such as 1-, 2-, or 4-vinylimidazole. In certainembodiments, the heterocyclic nitrogen groups are 4-vinylpyridine, suchthat the polymer is a derivative of poly(4-vinylpyridine). The terms“polyvinylpyridine” or “PVP” refer to poly(4-vinylpyridine),poly(3-vinylpyridine), or poly(2-vinylpyridine), as well as anycopolymer of vinylpyridine and a second or a third copolymer component.An example of such a poly(4-vinylpyridine) membrane has the followinggeneral formula, Formula II:

wherein the horizontal line represents a polymer backbone and n is apositive integer. A further example of such a poly(4-vinylpyridine)membrane has the following general formula, Formula III

wherein n is a positive integer.

In some embodiments, the membranes further include a crosslinking agent.A “crosslinker” is a molecule that contains at least two reactive groupscapable of linking at least two molecules together, or linking at leasttwo portions of the same molecule together. Linking of at least twomolecules is called intermolecular crosslinking, while linking of atleast two portions of the same molecule is called intramolecularcrosslinking. A crosslinker having more than two reactive groups may becapable of both intermolecular and intramolecular crosslinkings at thesame time. A “reactive group” is a functional group of a molecule thatis capable of reacting with another compound to couple at least aportion of that other compound to the molecule. Reactive groups includecarboxy, activated ester, sulfonyl halide, sulfonate ester, isocyanate,isothiocyanate, epoxide, aziridine, halide, aldehyde, ketone, amine,acrylamide, thiol, acyl azide, acyl halide, hydrazine, hydroxylamine,alkyl halide, imidazole, pyridine, phenol, alkyl sulfonate,halotriazine, imido ester, maleimide, hydrazide, hydroxy, andphoto-reactive azido aryl groups. Activated esters, as understood in theart, generally include esters of succinimidyl, benzotriazolyl, or arylsubstituted by electron-withdrawing groups such as sulfo, nitro, cyano,or halo groups; or carboxylic acids activated by carbodiimides.

Crosslinkers suitable for use with the membranes include moleculeshaving at least two reactive groups, such as bi-, tri-, ortetra-functional groups, capable of reacting with the heterocyclicnitrogen groups, such as the pyridine groups, of the polymer. Suitablecrosslinkers include, but are not limited to, derivatives ofpoly(ethylene glycol) or poly(propylene glycol), epoxide (glycidylgroup), aziridine, alkyl halide, and sulfonate esters. Alkylating groupsof the crosslinkers are preferably glycidyl groups. Preferably, glycidylcrosslinkers have a molecular weight of from about 200 to about 4,000and are water soluble or soluble in a water-miscible solvent, such as analcohol. Examples of suitable crosslinkers include, but are not limitedto, poly(ethylene glycol) diglycidyl ether with a molecular weight ofabout 250 to about 2000, including about 350 to about 150, such as about650. An exemplary crosslinker has the following general formula, FormulaIV:

wherein n is a positive integer, such as from about 1 to about 15,including about 8, 9, 10, 11, etc.

In certain embodiments, it is desirable to have a slow crosslinkingreaction during the dispensing of membrane solution so that the membranecoating solution has a reasonable pot-life for large-scale manufacture.A fast crosslinking reaction results in a coating solution of rapidlychanging viscosity, which renders coating difficult. For example, thecrosslinking reaction is slow during the dispensing of the membranesolution, and accelerated during the curing of the membrane at ambienttemperature, or at an elevated temperature where possible.

An example of a process for producing a membrane is now described. Forexample, the polymer and a suitable crosslinker are dissolved in abuffer-containing solvent, typically a buffer-alcohol mixed solvent, toproduce a membrane solution. In some embodiments, the buffer has a pH ofabout 7.5 to about 9.5 and the alcohol is ethanol. For example, thebuffer is a 10 mM (2-(4-(2-hydroxyethyl)-1-piperazine)ethanesulfonate)(HEPES) buffer (pH 8) and the ethanol to buffer volume ratio is fromabout 95 to 5 to about 0 to 100. A minimum amount of buffer is necessaryfor the crosslinking chemistry. The amount of solvent needed to dissolvethe polymer and the crosslinker may vary depending on the nature of thepolymer and the crosslinker. For example, a higher percentage of alcoholmay be required to dissolve a relatively hydrophobic polymer and/orcrosslinker.

The ratio of polymer to cross-linker is important to the nature of thefinal membrane. By way of example, if an inadequate amount ofcrosslinker or an extremely large excess of crosslinker is used,crosslinking is insufficient and the membrane is weak. Further, if amore than adequate amount of crosslinker is used, the membrane is overlycrosslinked such that membrane is too brittle and/or impedes analytediffusion. Thus, there is an optimal ratio of a given polymer to a givencrosslinker that should be used to prepare a desirable or usefulmembrane. By way of example, the optimal polymer to crosslinker ratio byweight is typically from about 4:1 to about 32:1 for a polymer of any ofFormulas I to III above and a poly(ethylene glycol) diglycidyl ethercrosslinker, having a molecular weight of about 200 to about 400. Forexample, this range is from about 2:1 to about 25:1, including about 3:1to about 22:1, about 4:1 to about 20:1, about 5:1 to about 16:1, etc.Further by way of example, the optimal polymer to crosslinker ratio byweight is typically about 10:1 for a polymer of Formula III above and apoly(ethylene glycol) diglycidyl ether crosslinker having a molecularweight of about 650.

The membrane solution can be coated over a variety of biosensors thatmay benefit from having a membrane disposed over the enzyme-containingsensing layer. A “sensing layer” is a component of the sensor whichincludes constituents that facilitate the electrolysis of the analyte.The sensing layer may include constituents such as an electron transferagent, a catalyst which catalyzes a reaction of the analyte to produce aresponse at the electrode, or both. In some embodiments of the sensor,the sensing layer is non-leachably disposed in proximity to or on theworking electrode. A “non-leachable” or “non-releasable” compound or acompound that is “non-leachably disposed” is meant to define a compoundthat is affixed on the sensor such that it does not substantiallydiffuse away from the working surface of the working electrode for theperiod in which the sensor is used (e.g., the period in which the sensoris implanted in a patient or measuring a sample). A “working surface” isthat portion of the working electrode which is coated with or isaccessible to the electron transfer agent and configured for exposure toan analyte-containing fluid.

In some embodiments, the sending layer further includes a redoxmediator. A “redox mediator” is an electron-transfer agent for carryingelectrons in one or more of the steps of the signal producing reactionor the reactions, for example between an analyte, an analyte-reduced oranalyte-oxidized enzyme, and an electrode, either directly, or via oneor more additional electron-transfer agents. A redox mediator thatincludes a polymeric backbone may also be referred to as a “redoxpolymer”. Examples of redox mediators include ruthenium-containingcomplexes and osmium-containing complexes.

Examples of such biosensors include, but are not limited to, glucosesensors and lactate sensors. (See U.S. Pat. No. 6,134,461 to Heller etal., which is incorporated herein in its entirety by this reference.)The coating process may comprise any commonly used technique, such asspin-coating, dip-coating, doctor blading or dispensing droplets of themembrane solution over the sensing layers, and the like, followed bycuring under ambient conditions typically for 1 to 2 days. Theparticular details of the coating process (such as dip duration, dipfrequency, number of dips, or the like) may vary.

Sensor fabrication typically includes depositing an enzyme-containingsensing layer over a working electrode and casting thediffusion-limiting membrane layer over the sensing layer, andoptionally, but preferably, also over the counter and referenceelectrodes. Sensors having other configurations such as athree-electrode design can also be prepared using similar methods.

Electrochemical Sensors

An electrochemical sensor that includes at least one working electrodewith membranes including heterocyclic nitrogen groups, such aspolyvinylpyridine, disposed thereon can be formed on a substrate. Thesensor may also include at least one counter electrode (orcounter/reference electrode) and/or at least one reference electrode. An“electrochemical sensor” is a device configured to detect the presenceand/or measure the level of an analyte in a sample, via anelectrochemical oxidation or reduction reaction on the sensor, or via asequence of chemical reactions where at least one of the chemicalreactions is an electrochemical oxidation or reduction reactions on thesensor. These reactions are transduced to an electrical signal that canbe correlated to an amount, concentration, or level of an analyte in thesample.

A “working electrode” is an electrode at which the analyte, or acompound whose level depends on the level of the analyte, iselectrooxidized or electroreduced with or without the agency of anelectron transfer agent. A “counter electrode” refers to an electrodepaired with the working electrode, through which passes a current aboutequal in magnitude and opposite in sign to the current passing throughthe working electrode. In the context of the invention, the term“counter electrode” is meant to include counter electrodes which alsofunction as reference electrodes (i.e., a counter/reference electrode).The term “reference electrode” includes both a) reference electrodes andb) reference electrodes that also function as counter electrodes (i.e.,counter/reference electrodes), unless otherwise indicated. The term“counter electrode” includes both a) counter electrodes and b) counterelectrodes that also function as reference electrodes (i.e.,counter/reference electrodes), unless otherwise indicated.

The counter electrode and/or reference electrode may be formed on thesubstrate or may be separate. For example, the counter electrode and/orreference electrode may be formed on a second substrate which is alsoimplanted in the patient or, for some embodiments of the implantablesensors, the counter electrode and/or reference electrode may be placedon the skin of the patient with the working electrode or electrodesbeing implanted into the patient. The use of an on-the-skin counterand/or reference electrode with an implantable working electrode isdescribed in U.S. Pat. No. 5,593,852.

The working electrode or electrodes are formed using conductive tracesdisposed on the substrate. The counter electrode and/or referenceelectrode, as well as other optional portions of the sensor, such as atemperature probe, may also be formed using conductive traces disposedon the substrate. These conductive traces may be formed over a smoothsurface of the substrate or within channels formed by, for example,embossing, indenting or otherwise creating a depression in thesubstrate.

The sensing layer is often formed proximate to or on at least one of theworking electrodes to facilitate the electrochemical detection of theanalyte and the determination of its level in the sample fluid,particularly if the analyte can not be electrolyzed at a desired rateand/or with a desired specificity on a bare electrode. The sensing layermay include an electron transfer agent to transfer electrons directly orindirectly between the analyte and the working electrode. An “electrontransfer agent” is a compound that carries electrons between the analyteand the working electrode, either directly, or in cooperation with otherelectron transfer agents. One example of an electron transfer agent is aredox mediator.

The sensing layer may also contain a catalyst to catalyze a reaction ofthe analyte. The components of the sensing layer may be in a fluid orgel that is proximate to or in contact with the working electrode.Alternatively, the components of the sensing layer may be disposed in apolymeric or sol-gel matrix that is proximate to or on the workingelectrode. In general, the components of the sensing layer arenon-leachably disposed within the sensor. For example, the components ofthe sensor are immobilized within the sensor. In addition to theelectrodes and the sensing layer, the sensor may also include atemperature probe, a biocompatible layer, and/or other optionalcomponents. A compound is “immobilized” on a surface when it isentrapped on or chemically bound to the surface. Components are“immobilized” within a sensor, for example, when the components arecovalently, ionically, or coordinatively bound to constituents of thesensor and/or are entrapped in a polymeric or sol-gel matrix or membranewhich precludes their loss by out-diffusion.

For example, a glucose or lactate sensor may include a first sensinglayer which is spaced apart from the working electrode and contains anenzyme, for example, glucose oxidase or lactate oxidase. The reaction ofglucose or lactate in the presence of the appropriate enzyme formshydrogen peroxide. A second sensing layer is provided directly on theworking electrode and contains a peroxidase enzyme and an electrontransfer agent to generate a signal at the electrode in response to thehydrogen peroxide. The level of hydrogen peroxide indicated by thesensor then correlates to the level of glucose or lactate. Anothersensor which operates similarly can be made using a single sensing layerwith both the glucose or lactate oxidase and the peroxidase beingdeposited in the single sensing layer. Examples of such sensors aredescribed in U.S. Pat. No. 5,593,852, U.S. patent application Ser. No.08/540,789, and PCT Patent Application No. US98/02403.

In some embodiments, one or more of the working electrodes do not have acorresponding sensing layer, or have a sensing layer which does notcontain one or more components (e.g., an electron transfer agent orcatalyst) needed to electrolyze the analyte. The signal generated atthis working electrode typically arises from interferents and othersources, such as electrooxidizable or electroreducible ions, in thefluid, and not in response to the analyte (because the analyte is notelectrooxidized or electroreduced). Thus, the signal at this workingelectrode adds to a background signal. The background signal can besubtracted from the analyte signal obtained from other workingelectrodes that are associated with fully-functional sensing layers.

The substrate may be formed using a variety of non-conducting materials,including, for example, polymeric or plastic materials and ceramicmaterials. Suitable materials for a particular sensor may be determined,at least in part, based on the desired use of the sensor and propertiesof the materials.

In some embodiments, the substrate is flexible. For example, if thesensor is configured for implantation into a patient, then the sensormay be made flexible (although rigid sensors may also be used forimplantable sensors) to reduce pain to the patient and damage to thetissue caused by the implantation of and/or the wearing of the sensor. Aflexible substrate often increases the patient's comfort and allows awider range of activities. Suitable materials for a flexible substrateinclude, for example, non-conducting plastic or polymeric materials andother non-conducting, flexible, deformable materials. Examples of usefulplastic or polymeric materials include thermoplastics such aspolycarbonates, polyesters (e.g., Mylar™ and polyethylene terephthalate(PET)), polyvinyl chloride (PVC), polyurethanes, polyethers, polyamides,polyimides, or copolymers of these thermoplastics, such as PETG(glycol-modified polyethylene terephthalate).

In other embodiments, the sensors are made using a relatively rigidsubstrate to, for example, provide structural support against bending orbreaking. Examples of rigid materials that may be used as the substrateinclude poorly conducting ceramics, such as aluminum oxide and silicondioxide. One advantage of an implantable sensor having a rigid substrateis that the sensor may have a sharp point and/or a sharp edge to aid inimplantation of a sensor without an additional insertion device.

It will be appreciated that for many sensors and sensor applications,both rigid and flexible sensors will operate adequately. The flexibilityof the sensor may also be controlled and varied along a continuum bychanging, for example, the composition and/or thickness of thesubstrate.

In addition to considerations regarding flexibility, it is oftendesirable that implantable sensors should have a substrate which isphysiologically harmless, for example, a substrate approved by aregulatory agency or private institution for in vivo use.

The sensor may include optional features to facilitate insertion of animplantable sensor. For example, the sensor may be pointed at the tip toease insertion. In addition, the sensor may include a barb which assistsin anchoring the sensor within the tissue of the patient duringoperation of the sensor. However, the barb is typically small enough sothat little damage is caused to the subcutaneous tissue when the sensoris removed for replacement.

At least one conductive trace is formed on the substrate for use inconstructing a working electrode. In addition, other conductive tracesmay be formed on the substrate for use as electrodes (e.g., additionalworking electrodes, as well as counter, counter/reference, and/orreference electrodes) and other components, such as a temperature probe.The conductive traces may extend most of the distance along a length ofthe sensor, although this is not necessary. The placement of theconductive traces may depend on the particular configuration of theanalyte monitoring system (e.g., the placement of control unit contactsand/or the sample chamber in relation to the sensor). For implantablesensors, particularly subcutaneously implantable sensors, the conductivetraces typically extend close to the tip of the sensor to minimize theamount of the sensor that must be implanted.

Typically, each of the conductive traces includes a contact pad. Thecontact pad may simply be a portion of the conductive trace that isindistinguishable from the rest of the trace except that the contact padis brought into contact with the conductive contacts of a control unit(e.g., the sensor control unit). More commonly, however, the contact padis a region of the conductive trace that has a larger width than otherregions of the trace to facilitate a connection with the contacts on thecontrol unit. By making the contact pads relatively large as comparedwith the width of the conductive traces, the need for preciseregistration between the contact pads and the contacts on the controlunit is less critical than with small contact pads.

To electrolyze the analyte, a potential (versus a reference potential)is applied across the working and counter electrodes. The minimummagnitude of the applied potential is often dependent on the particularelectron transfer agent, analyte (if the analyte is directlyelectrolyzed at the electrode), or second compound (if a secondcompound, such as oxygen or hydrogen peroxide, whose level is dependenton the analyte level, is directly electrolyzed at the electrode). Theapplied potential usually equals or is more oxidizing or reducing,depending on the desired electrochemical reaction, than the redoxpotential of the electron transfer agent, analyte, or second compound,whichever is directly electrolyzed at the electrode. The potential atthe working electrode is typically large enough to drive theelectrochemical reaction to or near completion.

When a potential is applied between the working electrode and thecounter electrode, an electrical current will flow. The current is aresult of the electrolysis of the analyte or a second compound whoselevel is affected by the analyte. “Electrolysis” is the electrooxidationor electroreduction of a compound either directly at an electrode or viaone or more electron transfer agents. In one embodiment, theelectrochemical reaction occurs via an electron transfer agent and theoptional catalyst. Many analytes B are oxidized (or reduced) to productsC by an electron transfer agent species A in the presence of anappropriate catalyst (e.g., an enzyme). The electron transfer agent A isthen oxidized (or reduced) at the electrode. Electrons are collected by(or removed from) the electrode and the resulting current is measured.

As an example, an electrochemical sensor may be based on the reaction ofa glucose molecule with two non-leachable ferricyanide anions in thepresence of glucose oxidase to produce two non-leachable ferrocyanideanions, two hydrogen ions, and gluconolactone. The amount of glucosepresent is assayed by electrooxidizing the non-leachable ferrocyanideanions to non-leachable ferricyanide anions and measuring the current.

An implantable sensor may also, optionally, have an anticlotting agentdisposed on a portion the substrate which is implanted into a patient.This anticlotting agent may reduce or eliminate the clotting of blood orother body fluid around the sensor, particularly after insertion of thesensor. Blood clots may foul the sensor or irreproducibly reduce theamount of analyte which diffuses into the sensor. Examples of usefulanticlotting agents include heparin and tissue plasminogen activator(TPA), as well as other known anticlotting agents.

The anticlotting agent may be applied to at least a portion of that partof the sensor that is to be implanted. The anticlotting agent may beapplied, for example, by bath, spraying, brushing, or dipping. Theanticlotting agent is allowed to dry on the sensor. The anticlottingagent may be immobilized on the surface of the sensor or it may beallowed to diffuse away from the sensor surface. Typically, thequantities of anticlotting agent disposed on the sensor are far belowthe amounts typically used for treatment of medical conditions involvingblood clots and, therefore, have only a limited, localized effect.

By way of example, the membrane may be used in a two-electrodeamperometric glucose sensor, as shown in FIGS. 4A-4C (collectively FIG.4). The amperometric glucose sensor 10 a of FIG. 4 includes a substrate13 disposed between a working electrode 29 a that is typicallycarbon-based, and an Ag/AgCl counter/reference electrode 29 b. A sensoror sensing layer 18 a is disposed on the working electrode. A membraneor membrane layer 30 a encapsulates the entire glucose sensor 10 a,including the Ag/AgCl counter/reference electrode. The sensing layer 18a of the glucose sensor 10 a includes, for example, crosslinked glucoseoxidase and a low potential polymeric osmium complex mediator, asdisclosed in the above-mentioned Published PCT Application,International Publication No. WO 01/36660 A2. The enzyme- andmediator-containing formulation that can be used in the sensing layer,and methods for applying them to an electrode system, are known in theart, for example, from the above-mentioned U.S. Pat. No. 6,134,461 ofSay et al.

By way of example, the membrane may also be used in stacked electrodeglucose sensor, as shown in FIG. 5. FIG. 5 illustrates a fullyfabricated sensor, with a catalytic agent incorporated into a protectivemembrane, as the sensor would be seen placed on the skin, with a portionof the sensor transcutaneously inserted into the subcutaneous space.FIG. 5 provides a perspective view of a sensor 10 a, the major portionof which is above the surface of the skin 50, with an insertion tip 11penetrating through the skin and into the subcutaneous space 52, whereit is bathed in biofluid 40. Contact portions of a working electrode 29aa, a reference electrode 29 bb, and a counter electrode 29 cc can beseen on the portion of the sensor 10 a situated above the skin surface.Working electrode 29 a, a reference electrode 29 b, and a counterelectrode 29 c can be seen at the end of the insertion tip 11. As shownin FIG. 5 the electrodes are provided in a stacked configuration on thesensor insertion tip 11. The working electrode 29 a is shown resting ontop of a plastic substrate 13, a wired enzyme sensing layer 18 a restson top of a portion of the working electrode 29 a. Overlaying thesensing layer and a portion of the electrode, depicted transparently, isan interfacing membrane 30 a, and associated with and dispersedthroughout the membrane is a catalytic agent 32, the membrane coveringthe sensing layer 18 a of the enzyme-based electrochemical sensor. Thetip 11 is in the subcutaneous space 52 (as seen in FIG. 5) and isconsequently bathed in the surrounding biofluid 40. The catalytic agentis dispersed in the membrane by admixing into the membrane solution usedin the synthesis of the membrane, a bulk loading procedure, as describedin U.S. patent application Ser. No. 10/819,498 of Feldman et al., filedon Apr. 6, 2004.

Insertion Device

An insertion device can be used to subcutaneously insert the sensor intothe patient. The insertion device is typically formed using structurallyrigid materials, such as metal or rigid plastic. Preferred materialsinclude stainless steel and ABS (acrylonitrile-butadiene-styrene)plastic. In some embodiments, the insertion device is pointed and/orsharp at the tip to facilitate penetration of the skin of the patient. Asharp, thin insertion device may reduce pain felt by the patient uponinsertion of the sensor. In other embodiments, the tip of the insertiondevice has other shapes, including a blunt or flat shape. Theseembodiments may be particularly useful when the insertion device doesnot penetrate the skin but rather serves as a structural support for thesensor as the sensor is pushed into the skin.

Sensor Control Unit

The sensor control unit can be integrated in the sensor, part or all ofwhich is subcutaneously implanted or it can be configured to be placedon the skin of a patient. The sensor control unit is optionally formedin a shape that is comfortable to the patient and which may permitconcealment, for example, under a patient's clothing. The thigh, leg,upper arm, shoulder, or abdomen are convenient parts of the patient'sbody for placement of the sensor control unit to maintain concealment.However, the sensor control unit may be positioned on other portions ofthe patient's body. One embodiment of the sensor control unit has athin, oval shape to enhance concealment. However, other shapes and sizesmay be used.

The particular profile, as well as the height, width, length, weight,and volume of the sensor control unit may vary and depends, at least inpart, on the components and associated functions included in the sensorcontrol unit. In general, the sensor control unit includes a housingtypically formed as a single integral unit that rests on the skin of thepatient. The housing typically contains most or all of the electroniccomponents of the sensor control unit.

The housing of the sensor control unit may be formed using a variety ofmaterials, including, for example, plastic and polymeric materials,particularly rigid thermoplastics and engineering thermoplastics.Suitable materials include, for example, polyvinyl chloride,polyethylene, polypropylene, polystyrene, ABS polymers, and copolymersthereof. The housing of the sensor control unit may be formed using avariety of techniques including, for example, injection molding,compression molding, casting, and other molding methods. Hollow orrecessed regions may be formed in the housing of the sensor controlunit. The electronic components of the sensor control unit and/or otheritems, such as a battery or a speaker for an audible alarm, may beplaced in the hollow or recessed areas.

The sensor control unit is typically attached to the skin of thepatient, for example, by adhering the sensor control unit directly tothe skin of the patient with an adhesive provided on at least a portionof the housing of the sensor control unit which contacts the skin or bysuturing the sensor control unit to the skin through suture openings inthe sensor control unit.

When positioned on the skin of a patient, the sensor and the electroniccomponents within the sensor control unit are coupled via conductivecontacts. The one or more working electrodes, counter electrode (orcounter/reference electrode), optional reference electrode, and optionaltemperature probe are attached to individual conductive contacts. Forexample, the conductive contacts are provided on the interior of thesensor control unit. Other embodiments of the sensor control unit havethe conductive contacts disposed on the exterior of the housing. Theplacement of the conductive contacts is such that they are in contactwith the contact pads on the sensor when the sensor is properlypositioned within the sensor control unit.

Sensor Control Unit Electronics

The sensor control unit also typically includes at least a portion ofthe electronic components that operate the sensor and the analytemonitoring device system. The electronic components of the sensorcontrol unit typically include a power supply for operating the sensorcontrol unit and the sensor, a sensor circuit for obtaining signals fromand operating the sensor, a measurement circuit that converts sensorsignals to a desired format, and a processing circuit that, at minimum,obtains signals from the sensor circuit and/or measurement circuit andprovides the signals to an optional transmitter. In some embodiments,the processing circuit may also partially or completely evaluate thesignals from the sensor and convey the resulting data to the optionaltransmitter and/or activate an optional alarm system if the analytelevel exceeds a threshold. The processing circuit often includes digitallogic circuitry.

The sensor control unit may optionally contain a transmitter fortransmitting the sensor signals or processed data from the processingcircuit to a receiver/display unit; a data storage unit for temporarilyor permanently storing data from the processing circuit; a temperatureprobe circuit for receiving signals from and operating a temperatureprobe; a reference voltage generator for providing a reference voltagefor comparison with sensor-generated signals; and/or a watchdog circuitthat monitors the operation of the electronic components in the sensorcontrol unit.

Moreover, the sensor control unit may also include digital and/or analogcomponents utilizing semiconductor devices, such as transistors. Tooperate these semiconductor devices, the sensor control unit may includeother components including, for example, a bias control generator tocorrectly bias analog and digital semiconductor devices, an oscillatorto provide a clock signal, and a digital logic and timing component toprovide timing signals and logic operations for the digital componentsof the circuit.

As an example of the operation of these components, the sensor circuitand the optional temperature probe circuit provide raw signals from thesensor to the measurement circuit. The measurement circuit converts theraw signals to a desired format, using for example, a current-to-voltageconverter, current-to-frequency converter, and/or a binary counter orother indicator that produces a signal proportional to the absolutevalue of the raw signal. This may be used, for example, to convert theraw signal to a format that can be used by digital logic circuits. Theprocessing circuit may then, optionally, evaluate the data and providecommands to operate the electronics.

Calibration

In general, the calibration is preferably performed by measuring asignal at a particular point in time, meaning by one point calibration,as described in U.S. Pat. No. 5,593,852.

In addition to a transmitter, an optional receiver may be included inthe sensor control unit. In some cases, the transmitter is atransceiver, operating as both a transmitter and a receiver. Thereceiver may be used to receive calibration data for the sensor. Thecalibration data may be used by the processing circuit to correctsignals from the sensor. This calibration data may be transmitted by thereceiver/display unit or from some other source such as a control unitin a doctor's office. In addition, the optional receiver may be used toreceive a signal from the receiver/display units to direct thetransmitter, for example, to change frequencies or frequency bands, toactivate or deactivate the optional alarm system and/or to direct thetransmitter to transmit at a higher rate.

Calibration data may be obtained in a variety of ways. For instance, thecalibration data may simply be factory-determined calibrationmeasurements which can be input into the sensor control unit using thereceiver or may alternatively be stored in a calibration data storageunit within the sensor control unit itself (in which case a receiver maynot be needed). The calibration data storage unit may be, for example, areadable or readable/writeable memory circuit.

Alternative or additional calibration data may be provided based ontests performed by a doctor or some other professional or by thepatient. For example, it is common for diabetic individuals to determinetheir own blood glucose concentration using commercially availabletesting kits. The results of this test is input into the sensor controlunit either directly, if an appropriate input device (e.g., a keypad, anoptical signal receiver, or a port for connection to a keypad orcomputer) is incorporated in the sensor control unit, or indirectly byinputting the calibration data into the receiver/display unit andtransmitting the calibration data to the sensor control unit.

Other methods of independently determining analyte levels may also beused to obtain calibration data. This type of calibration data maysupplant or supplement factory-determined calibration values.

In some embodiments of the invention, calibration data may be requiredat periodic intervals, for example, every eight hours, once a day, oronce a week, to confirm that accurate analyte levels are being reported.Calibration may also be required each time a new sensor is implanted orif the sensor exceeds a threshold minimum or maximum value or if therate of change in the sensor signal exceeds a threshold value. In somecases, it may be necessary to wait a period of time after theimplantation of the sensor before calibrating to allow the sensor toachieve equilibrium. In some embodiments, the sensor is calibrated onlyafter it has been inserted. In other embodiments, no calibration of thesensor is needed.

Analyte Monitoring Device

In some embodiments of the invention, the analyte monitoring deviceincludes a sensor control unit and a sensor. In these embodiments, theprocessing circuit of the sensor control unit is able to determine alevel of the analyte and activate an alarm system if the analyte levelexceeds a threshold. The sensor control unit, in these embodiments, hasan alarm system and may also include a display, such as an LCD or LEDdisplay.

A threshold value is exceeded if the datapoint has a value that isbeyond the threshold value in a direction indicating a particularcondition. For example, a datapoint which correlates to a glucose levelof 200 mg/dL exceeds a threshold value for hyperglycemia of 180 mg/dL,because the datapoint indicates that the patient has entered ahyperglycemic state. As another example, a datapoint which correlates toa glucose level of 65 mg/dL exceeds a threshold value for hypoglycemiaof 70 mg/dL because the datapoint indicates that the patient ishypoglycemic as defined by the threshold value. However, a datapointwhich correlates to a glucose level of 75 mg/dL would not exceed thesame threshold value for hypoglycemia because the datapoint does notindicate that particular condition as defined by the chosen thresholdvalue.

An alarm may also be activated if the sensor readings indicate a valuethat is beyond a measurement range of the sensor. For glucose, thephysiologically relevant measurement range is typically about 50 to 250mg/dL, preferably about 40-300 mg/dL and ideally 30-400 mg/dL, ofglucose in the interstitial fluid.

The alarm system may also, or alternatively, be activated when the rateof change or acceleration of the rate of change in analyte levelincrease or decrease reaches or exceeds a threshold rate oracceleration. For example, in the case of a subcutaneous glucosemonitor, the alarm system might be activated if the rate of change inglucose concentration exceeds a threshold value which might indicatethat a hyperglycemic or hypoglycemic condition is likely to occur.

EXAMPLES

The following examples are put forth so as to provide those of ordinaryskill in the art with a complete disclosure and description of how tomake and use the present invention, and are not intended to limit thescope of what the inventors regard as their invention nor are theyintended to represent that the experiments below are all or the onlyexperiments performed. Efforts have been made to ensure accuracy withrespect to numbers used (e.g. amounts, temperature, etc.) but someexperimental errors and deviations should be accounted for. Unlessindicated otherwise, parts are parts by weight, molecular weight isweight average molecular weight, temperature is in degrees Centigrade,and pressure is at or near atmospheric.

Example 1 Calibration Experiment

In a first example, a calibration experiment was conducted in which twosensors (PVP1 and PVP2) having diffusion-limiting membranes describedherein were tested simultaneously, both at 37° C. The membranes wereprepared from polymers of Formula III above and poly(ethylene glycol)diglycidyl ether (PEGDGE) crosslinkers, having a molecular weight ofabout 650. In the calibration experiment for each of PVP1 and PVP2, thesensors were placed in a PBS-buffered solution (pH 7) and the outputcurrent of each of the sensors was measured over time (FIG. 1) or as theglucose concentration was increased (FIG. 2). The measured outputcurrents (nA) for each of PVP1 and PVP2 was determined and plottedagainst either time, as shown in the calibration graph of FIG. 1, orglucose concentration (mM), as shown in the calibration graph of FIG. 2.

As shown in FIG. 2, the calibration curve for the two sensors havingdiffusion-limiting membranes described herein are substantially linearover a relatively large range of glucose concentrations, for example,from zero to about 30 mM, as demonstrated by the best-fit line for thePVP1 sensor (y=0.4318x+0.7613; R²=0.9967) and the PVP2 sensor(y=0.4424x+0.3701; R²=0.9964). This result demonstrates the considerablesensitivity of the membrane-equipped membranes to glucose concentration,at low, medium, and high glucose concentrations, and of particularrelevance, at the high end of clinically relevant glucose concentrationat about 30 mM.

Example 2 Stability Experiment

In a second example, a stability experiment was conducted in which twosensors having diffusion-limiting membranes were tested, simultaneously,at 37° C. The sensors had membranes prepared from the same polymer andthe same crosslinker as those of the sensors described above in thecalibration experiment. In this stability experiment, each of thesensors was placed in a PBS-buffered solution (pH 7) at variousconcentrations of glucose, and the output current of each of the sensorswas measured at either room temperature (RT) or used after storage for 1week at 56° C. (56 C/1 wk). The measured output currents (nA) wereplotted against concentrations of glucose (mM), as shown in thestability graph of FIG. 3.

As shown in FIG. 3, the stability curve for the two sensors havingdiffusion-limiting membranes is substantially linear over a relativelylarge range of glucose concentrations, for example, from zero to about30 mM, as demonstrated by the best-fit line for the RT sensor(y=0.5535x+0.8031; R²=0.9952) and the 56 C/1 wk sensor (y=0.6828x+1.183;R²=0.993). This result demonstrates the considerable stability andreliability of the membrane-equipped sensors described herein.

The preceding merely illustrates the principles of the invention. Itwill be appreciated that those skilled in the art will be able to devisevarious arrangements which, although not explicitly described or shownherein, embody the principles of the invention and are included withinits spirit and scope. Furthermore, all examples and conditional languagerecited herein are principally intended to aid the reader inunderstanding the principles of the invention and the conceptscontributed by the inventors to furthering the art, and are to beconstrued as being without limitation to such specifically recitedexamples and conditions. Moreover, all statements herein recitingprinciples, aspects, and embodiments of the invention as well asspecific examples thereof, are intended to encompass both structural andfunctional equivalents thereof. Additionally, it is intended that suchequivalents include both currently known equivalents and equivalentsdeveloped in the future, i.e., any elements developed that perform thesame function, regardless of structure. The scope of the presentinvention, therefore, is not intended to be limited to the exemplaryembodiments shown and described herein. Rather, the scope and spirit ofpresent invention is embodied by the appended claims.

1. An electrochemical sensor, comprising: a working electrodecomprising: a sensing layer in contact with a conductive material of theelectrode; a membrane disposed over the sensing layer, wherein themembrane comprises a crosslinker and a polymer having the formula:

wherein the solid horizontal line represents a polymer backbone and n isa positive integer; and a counter electrode in electrochemicalcommunication with the working electrode.
 2. The electrochemical sensorof claim 1, wherein the sensing layer of the working electrode comprisesa glucose-responsive enzyme.
 3. The electrochemical sensor of claim 1,wherein the sensing layer of the working electrode comprises a redoxmediator.
 4. The electrochemical sensor of claim 3, wherein the redoxmediator comprises a complex selected from the group consisting of aruthenium-containing complex and an osmium-containing complex.
 5. Theelectrochemical sensor of claim 3, wherein the redox mediator isnon-leachable with respect to the working electrode.
 6. Theelectrochemical sensor of claim 3, wherein the redox mediator isimmobilized on the working electrode.
 7. The electrochemical sensor ofclaim 1, wherein the polymer comprises the formula:

wherein n is a positive integer.
 8. The electrochemical sensor of claim1, wherein the crosslinker comprises a poly(ethylene glycol).
 9. Theelectrochemical sensor of claim 8, wherein the poly(ethylene glycol) isa poly(ethylene glycol) diglycidyl ether.
 10. The electrochemical sensorof claim 1, wherein the membrane limits flux of glucose or lactatethereacross.
 11. The electrochemical sensor of claim 1, wherein themembrane limits flux of glucose or lactose thereacross in vivo.
 12. Anelectrode for use in a biosensor, comprising: a sensing layer in contactwith a conductive material of the electrode, and a membrane disposedover the sensing layer, wherein the membrane comprises a crosslinker anda polymer having the formula:

wherein the solid horizontal line represents a polymer backbone and n isa positive integer.
 13. The electrode of claim 12, wherein the sensinglayer of the working electrode comprises a glucose-responsive enzyme.14. The electrode of claim 12, wherein the sensing layer of the workingelectrode comprises a redox mediator.
 15. The electrode of claim 14,wherein the redox mediator comprises a complex selected from the groupconsisting of a ruthenium-containing complex and an osmium-containingcomplex.
 16. The electrode of claim 14, wherein the redox mediator isnon-leachable with respect to the working electrode.
 17. The electrodeof claim 14, wherein the redox mediator is immobilized on the workingelectrode.
 18. The electrode of claim 12, wherein the polymer comprisesthe formula:

wherein n is a positive integer.
 19. The electrode of claim 12, whereinthe crosslinker comprises a poly(ethylene glycol).
 20. The electrode ofclaim 19, wherein the poly(ethylene glycol) is a poly(ethylene glycol)diglycidyl ether.
 21. The electrode of claim 12, wherein the membranelimits flux of glucose or lactate thereacross.
 22. The electrode ofclaim 12, wherein the membrane limits flux of glucose or lactosethereacross in vivo.
 23. An analyte sensor assembly, comprising: anelectrochemical sensor comprising a flexible substrate comprising (i) atleast one working electrode comprising a sensing layer and a membranedisposed over the sensing layer, wherein the membrane comprises acrosslinker and a polymer having the formula:

wherein the solid horizontal line represents a polymer backbone and n isa positive integer, (ii) at least one counter electrode, and (iii) atleast one contact pad coupled to each of the working and counterelectrodes, wherein the electrochemical sensor is adapted forimplantation of a portion of the electrochemical sensor comprising theworking and counter electrodes through skin; and an electrochemicalsensor control unit comprising (i) a housing adapted for placement onskin; (ii) a plurality of conductive contacts disposed on the housingand configured for coupling to the contact pads of the electrochemicalsensor; and (iii) an rf transmitter disposed in the housing and coupledto the plurality of conductive contacts for transmitting data obtainedusing the electrochemical sensor.
 24. The analyte sensor of claim 23,wherein the sensing layer of the working electrode comprises aglucose-responsive enzyme.
 25. The analyte sensor of claim 23, whereinthe sensing layer of the working electrode comprises a redox mediator.26. The analyte sensor of claim 25, wherein the redox mediator comprisesa complex selected from the group consisting of a ruthenium-containingcomplex and an osmium-containing complex.
 27. The analyte sensor ofclaim 25, wherein the redox mediator is non-leachable with respect tothe working electrode.
 28. The analyte sensor of claim 25, wherein theredox mediator is immobilized on the working electrode.
 29. The analytesensor of claim 23, wherein the polymer comprises the formula:

wherein n is a positive integer.
 30. The analyte sensor of claim 23,wherein the crosslinker comprises a poly(ethylene glycol).
 31. Theanalyte sensor of claim 30, wherein the poly(ethylene glycol) is apoly(ethylene glycol) diglycidyl ether.
 32. The analyte sensor of claim23, wherein the membrane limits flux of glucose or lactate thereacross.33. The analyte sensor of claim 23, wherein the membrane limits flux ofglucose or lactose thereacross in vivo.
 34. A method for monitoring alevel of an analyte using the analyte monitoring system of claim 23, themethod comprising: inserting the electrochemical sensor into skin of apatient; attaching the electrochemical sensor control unit to the skinof the patient; coupling a plurality of conductive contacts disposed inthe sensor control unit to a plurality of contact pads disposed on thesensor; collecting data, using the sensor control unit, regarding alevel of an analyte from signals generated by the sensor; transmittingthe collected data to the display unit using the rf transmitter of thesensor control unit; and displaying an indication of the level of theanalyte on the display of the display unit.
 35. The method of claim 34,wherein the analyte is glucose.
 36. The method of claim 34, wherein thepolymer comprises the formula:

wherein n is a positive integer.
 37. The method of claim 34, wherein thecrosslinker comprises a poly(ethylene glycol).
 38. The method of claim37, wherein the poly(ethylene glycol) is a poly(ethylene glycol)diglycidyl ether.
 39. The method of claim 34, wherein collecting datacomprises generating signals from the sensor and processing the signalsinto data.
 40. The method of claim 34, wherein the data comprises thesignals from the sensor.
 41. The method of claim 34, further comprisingactivating an alarm if the data indicates an alarm condition.
 42. Themethod of claim 34, further comprising administering a drug in responseto the data.
 43. The method of claim 42, wherein the drug is insulin.44. The method of claim 43, further comprising obtaining a calibrationvalue from a calibration device to calibrate the data.
 45. The method ofclaim 44, wherein the calibration device is coupled to the display unit.46. The method of claim 45, further comprising transmitting thecalibration value from a transmitter in the display unit to a receiverin the sensor control unit.
 47. A membrane for use in an electrochemicalsensor, comprising: a crosslinker; and a polymer having the formula:

wherein the solid horizontal line represents a polymer backbone; D isselected from a group consisting of phenylalkyl, alkoxystyrene,hydroxyalkyl, alkoxyalkyl, alkoxycarbonylalkyl, a poly(ethyleneglycol)-containing constituent, and a polyhydroxyl-containingconstituent; and each of l, p and q is independently a positive number.48. The membrane of claim 47, wherein l is substituted with an aryl,alkoxy, alkenyl, alkynyl, -F, -Cl, -OH, aldehyde, ketone, ester, oramide.
 49. The membrane of claim 47, wherein D is styrene or C1-C18alkyl methacrylate.
 50. The membrane of claim 47, wherein the polymerhas a formula selected from the group consisting of:


51. The membrane of claim 47, wherein the polymer has a molecular weightof between about 50,000-1,000,000 kD.
 52. The membrane of claim 47,wherein the polymer further comprises a B-containing copolymer such thatthe polymer has the formula:

wherein B is a modifier and m is a positive number.
 53. The membrane ofclaim 52, wherein B is selected from a group consisting of a chelator, anegatively charged constituent, a hydrophobic hydrocarbon constituent, ahydrophilic hydroxyl or polyhydroxy constituent, a silicon polymer, anda poly(ethylene glycol).
 54. The membrane of claim 52, wherein B is apoly(ethylene glycol) having a molecular weight of from about 100 toabout 20,000 kD.
 55. The membrane of claim 52, wherein the polymer has aformula selected from the group consisting of:


56. An electrochemical sensor, comprising: a working electrodecomprising: a sensing layer in contact with a conductive material of theelectrode; a membrane disposed over the sensing layer, the membranecomprising a crosslinker and a polymer having the formula:

wherein the solid horizontal line represents a polymer backbone; D isselected from a group consisting of phenylalkyl, alkoxystyrene,hydroxyalkyl, alkoxyalkyl, alkoxycarbonylalkyl, a poly(ethyleneglycol)-containing constituent, and a polyhydroxyl-containingconstituent; and each of l, p and q is independently a positive number.57. The electrochemical sensor of claim 56, wherein l is substitutedwith an aryl, alkoxy, alkenyl, alkynyl, -F, -Cl, -OH, aldehyde, ketone,ester, or amide.
 58. The electrochemical sensor of claim 56, wherein Dis styrene or C1-C18 alkyl methacrylate.
 59. The electrochemical sensorof claim 56, wherein the polymer has a formula selected from the groupconsisting of:


60. The electrochemical sensor of claim 56, wherein the polymer has amolecular weight of between about 50,000-1,000,000 kD.